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Bureau of Mines Information Circular/1981 




Minerals Health and Safety 

In-House Research, Development, 

and Demonstration in Fiscal Year 1981 



By Staff, Division of Minerals Health 
and Safety Technology 




UNITED STATES DEPARTMENT OF THE INTERIOR 





Information Circular 8840 




Minerals Health and Safety 

In-House Research, Development, 

and Demonstration in Fiscal Year 1981 



By Staff, Division of Minerals Health 
and Safety Technology 




UNITED STATES DEPARTMENT OF THE INTERIOR 
James G. Watt, Secretary 

BUREAU OF MINES 






This publication has been cataloged as follows: 



United States. Bureau of Mines. Division of Minerals 
Healtli and Safety Technology 

Minerals health and safety in-house research, development, 
and demonstration in fiscal year 1981. 

(Information circular / United States Department of the Interior, 
Bureau of Mines ; 8840) 

1. Mine safety— United States. L Title. IL Series: Information 
circular (United States. Bureau of Mines) ; 8840. 



TN295.U4 622s [622'.8'0973] 81-1580 AACR2 



CONTENTS 

Page 

Abstract 1 

Introduction 1 

Program outline 2 

Health 3 

Respirable dust 3 

Control of dust formation 3 

Control of generated dust 3 

Dust instrumentation and measurement 4 

Radiation hazards 5 

Fundamental studies 5 

Control of radiation hazards 5 

Test facilities 6 

Noise control 6 

Industrial hygiene 7 

Toxic gases and materials 7 

Diesel engines and alternative power sources 8 

Ventilation 8 

Safety 9 

Fires and explosion prevention 9 

Prevention research 9 

Ignition research 9 

Suppression research 10 

Propagation research 10 

Extinguishment research 11 

Detection, instrumentation, and alarm 11 

Methane control 12 

Fundamental factors 12 

Control in advance of mining , 12 

Control during mining 13 

Ground control 14 

Premining investigations 14 

Selection of mining system and mine opening design 15 

Roof support system 18 

Safe support installation and protection at the face 20 

Hazard detection and monitoring systems 21 

Mining and minerals processing waste stability 24 

Indus trial -type hazards 25 

Human factors 25 

Electrical 25 

Equipment 26 

Illumination 27 

Nonemergency communications 27 

Haulage and materials handling 28 

Post disaster 29 

Survival 29 

Communications 29 



ii 



CONTENTS— Continued 

Page 

Explosives 30 

Blasting agents and other hazardous chemicals 30 

Systems engineering 31 

Systems analysis 32 

Test facilities 32 



MINERALS HEALTH AND SAFETY IN-HOUSE RESEARCH, 

DEVELOPMENT, AND DEMONSTRATION 

IN FISCAL YEAR 1981 

by 

Staff, Division of Minerals Health and Safety Technology 



ABSTRACT 



This publication summarizes, for all interested parties, the research, 
development, and demonstration in-house projects programed by the Bureau 
of Mines for fiscal year 1981 (October 1, 1980 - September 30, 1981) 
under its Minerals Health and Safety Technology program. The objective 
of these projects is to provide an ordered and sequenced series of 
advances toward the Bureau's overall goal of providing the system technology 
required to create a healthier and safer working environment for the 
Nation's mining and minerals processing workers. 



INTRODUCTION 



The Bureau of Mines conducts a balanced, continuing in-house research 
and development program to accelerate systematic improvements in health 
and safety conditions in U.S. mines. This paper outlines the Bureau's 
present in-house effort to all interested parties; in particular, potential 
contractors can refer to it when submitting USP's (unsolicited proposals), 
thus avoiding proposing research that duplicates work being performed by 
the Bureau. 

The projects presented were planned at the beginning of the fiscal 
year and are subject to change based on emerging priorities and availa- 
bility of funds. Contingencies may require that a significant portion 
of the program be deferred into fiscal year 1982. A companion publication. 
Information Circular 8839, lists contract projects. 



PROGRAM OUTLINE 

The objective of the Minerals Health and Safety Technology program 
is to protect the health and safety of mining and minerals processing 
workers while insuring that newly developed technology incorporates 
health and safety criteria. In achieving this objective, four fundamental 
and complementary requirements must be considered by the research program, 
as follows: 

1. Contributing to the viability of a basic industry. 

2. Sustaining productivity. 

3. Allowing for a return on capital investment. 

4. Providing material and energy to the public. 

Since mining and minerals processing involve a highly integrated 
and interrelated set of functions, the program has been divided into a 
set of interrelated subprograms, each with goals that will provide 
system.s technology solutions to the problems within the framework of 
these fundamental requirements. The Minerals Health and Safety Technology 
program is divided into 12 subprogram areas as shown: 

Health Safety 

Respirable dust Fires and explosion prevention 

Radiation hazards Methane control 

Noise control Ground control 

Industrial hygiene Industrial-type hazards 

Ventilation Post disaster 

Explosives 

Systems engineering 

The objectives of these subprograms are described in the following 

pages, followed by the planned projects and their corresponding descriptions, 

The aggregate value of the planned in-house projects is approximately 

$14 million. 



HEALTH 



Resplrable Dust 



Program Objectives ; To develop procedures for controlling the respirable 
dusts that still constitute the severest health problem facing the raining and 
mineral processing industries. To develop and/or improve techniques and 
equipment to prevent formation of hazardous dust concentrations, and to pro- 
tect miners against dusty atmospheres. 



Control of Dust Formation 



1. Reduction of Airborne Coal Dust With Increased Machine Efficiency 

Objective ; To develop background information in support of contract research 
related to reduction of primary dust generation at the bit-coal interface 
during cutting. To continue to determine the effects of water lubricity at 
the cutter-coal interface on primary dust generation and cutting forces. To 
continue bit wear studies and cooperative effort with Sandia Labs to develop 
new long-wearing cutting bits. 

2. Dust Control at the Cutter-Coal Interface 

Objective ; To define dust generation distribution patterns from rapidly 
moving cutting bits to evaluate optimum methods for secondary suppression of 
airborne respirable dust at the generation source. 



Control of Generated Dust 



3. Control of Respirable Dust by Water Infusion and Other Means of Pre- 
conditioning 

Objective ; To conduct underground evaluations to determine the effectiveness 
of water infusion for respirable dust control. Particular attention will be 
given to longwall mining operations in different coal seams. Work will also 
include evaluation of the physical properties of the coalbeds relating to 
fracture permeability and porosity. 

4. Dust Control by Chemicals and Chemical Additives 

Objective ; To continue to determine the potential of chemical (binders, 
salts, evaporative retardants, and surfactants) for reducing dust from 
underground coal mine roadways. To determine the effectiveness of rock dust 
with salts and other chemicals for dust control. To continue to evaluate the 
effectiveness of different wetting agents for different types of coals. 



5. Development of Dust Control Technology for Coal Mines 

Objective ; To conduct preliminary studies of concepts for improvements in 
dust control technology for coal mines. Primary consideration will be given 
to the application of shrouded high-pressure sprays and fog nozzles to improve 
the reliability and associated hardware, 

6. Dust Control Technology for Noncoal Mines and Mineral Processing Mills 

Objective ; To conduct preliminary studies leading to development of improved 
dust control technology for noncoal mines and mineral processing mills. To 
investigate dry dust control system for a loading machine. To develop a 
method of using tracer gas to determine capture efficiencies of various dust 
collector systems. To continue to evaluate current dust control technologies 
in silica-processing mills. 

7. Survey of Dust Control Problems 

Objective ; To continue the compilation of respirable dust sources and their 
control problems for mining and minerals processing operations. To analyze 
MSHA (Mine Safety and Health Administration) respirable dust data to establish 
the risks of occupational exposure. 

8. Control of Respirable Heavy Metal Dust in Lead Ore Milling Operations 

Objective ; To identify areas of heavy metal concentrations in respirable dust 
in typical lead milling environments and identify research necessary to modify 
existing processes or equipment to reduce personnel exposure to respirable 
heavy metals. 

9. Control of Respirable Dust Associated With Milling of Clays 

Objective; To obtain baseline data on clay mining and milling operations as 
related to health problems associated with respirable dust. To identify 
potential health problems and conduct research to develop technologies for 
control of respirable clay dusts. 

10. Suppression of Dust in Unconfined Clouds 

Objective ; To develop a fundamental understanding of the suppression of dust 
in unconfined clouds by water sprays and provide guidelines for optimizing 
water sprays for effective control of generated dust. 



Dust Instrumentation and Measurement 



11. Respirable Dust Measurement Instrumentation Evaluation 

Objective ; To continue evaluating dust samplers and monitors developed by 
Bureau contractors and others in the laboratory and in mines. Specific 
instruments to be evaluated include a prototype light reflectance photometer, 
light-scattering dust monitors, and various cascade impactors. To seek out 
new aerosol detection techniques and determine feasibility of applying them to 
the measurement needs of the mining industry. 



12. Characterization of Airborne Coal Dust 

Objective: To conduct special analysis of field dust collection filters pro- 
vided by MSHA and Bureau contractors. To characterize samples and measure the 
quartz content. To develop analytical procedures for accurate analysis of 
airborne coal dust. 

13 . Analytical Methods for Measurement and Characterization of Airborne 
Particulates 

Objective: To develop reliable methods for the qualitative and semiquanti- 
tative determination of mercury at mineral processing plants. These methods 
will be suitable for use by MSHA as well as plant personnel. To conduct 
special studies as requested by MSHA, which may include the characterization 
of mineral airborne fibrous particulates. 



Radiation Hazards 



Program Objectives : To develop and provide new and improved measurement 
instrumentation and control technology for protection of miners from exposure 
to radon and radon daughters and other nuclear radiation hazards in uranium 
and other mines. 



Fundamental Studies 



1 . Study of Underground Uranium Mill Waste Disposal Practices 

Objective : To define radiation hazards, possible improved corrective 
measures, and areas needing further research in uranium milling operations in 
relation to workers' health. Emphasis will be on underground disposal of the 
entire uranium mill tailings product. 



Control of Radiation Hazards 



2 . Radon Control Technology 

Objective : To continue to develop radon control technology for use in both 
underground and open pit uranium and other mines by investigating the engi- 
neering feasibility and cost effectiveness of using sealants, bulkheads, 
pressure control, tailings backfill, and moisture control in preventing or 
reducing radon leakage into the fresh airways. These studies will be explora- 
tory in nature. Evaluations of radon control techniques will be conducted 
primarily in the laboratory with limited in-mine testing of the most promising 
methods for the purpose of developing sound engineering guidelines for future 
full-scale development, in-mine testing, and demonstration. 



3 . Control of Radiation Hazards Through Air Cleaning 

Ob-jective : To continue research on the use of air-cleaning techniques for 
removal of radon daughters from underground mine atmospheres. To determine 
efficiencies, filter life with regard to moisture and airborne particle size, 
and concentration and characteristics of the radioactive components of the 
filtered air. To provide necessary technical assistance to the contractor 
during testing phase of a prototype air-cleaning system. 

4. Electronic Radon Daughter Personal Dosimeter 

Objective: To continue to make necessary modifications based on results of 
field testing. To verify the adequacy of modifications in the laboratory and 
field. To develop specifications for hardened version. To continue to 
explore the feasibility of using a hybrid detector in lieu of the current 
type. 

5. Personal Exposure Instrumentation and Measurement Technology 

Objective: To continue laboratory and field studies on instrumentation for 
exposure measurements and methods of making exposure measurement related to 
the miner's exposure to nuclear radiation hazards, with emphasis on the mea- 
surement of radon daughter products. Areas to be covered include (a) personal 
dosimeters, (b) area monitors, (c) shift monitors, (d) long-lived radionuclides 
in mine air, and (e) the uncombined fraction of daughter products in mine air. 
To begin development and evaluation of gamma ray personal dosimeters. To con- 
tinue to improve the accuracy and reliability of the current TL dosimeter 
system. 

6. Radiation Warning System for Uranium Mines 

Objective : To continue field evaluation of full system at large uranium 
mining and milling operations. To demonstrate stand-alone detector at smaller 
operations. To revise software and hardware to reflect improvements suggested 
by previous field tests. Modifications shall also be added to enable ventila- 
tion and other parameter monitoring. 



Test Facilities 



7 . Lease and Operate the Twilight Mine 

Objective : To continue to operate and maintain an underground uranium mine as 
a test facility to provide typical mine environmental conditions for research 
and development studies conducted by the Bureau of Mines, MSHA, other Govern- 
ment agencies, and outside contractors in the area of radiation hazards. 

Noise Control 



Program Objectives : To identify noise sources in underground and surface 
fnines and in related mineral cleaning and preparation facilities, and to abate 
these noise sources sufficiently to meet Federal noise exposure standards. 



1 . Development of Noise Control Techniques for Coal Mining Machinery 

Objective ; To further the implementation of noise control techniques to the 
mining industry. This will be accomplished via equipment development and dis- 
semination of information. 

2. Noise Study of Lead and Other Metal-Nonmetal Mining in the Central 
United States 

Objective ; To identify work areas in metal and nonmetal mines where noise 
exposure of personnel is most severe and the need for noise control technology 
is most urgent. 

Industrial Hygiene (Toxic Substances) 



Program Objectives ; To identify and control health hazards in surface and un- 
derground mines and mineral processing plants caused by toxic gases and fumes, 
and certain particulates produced by explosives, combustible materials, and 
diesel engines. To develop and evaluate new instrumentation for monitoring 
these substances. To develop and/or refine analytical techniques for mea- 
suring and characterizing toxic substances, and investigate methods for con- 
trolling the formation and accumulation of toxic products. To analyze alter- 
native power sources that may have health advantages over existing mine 
diesels. 



Toxic Gases and Material 



1. Toxic Fumes From Explosives 

Objective; To establish the relationship between toxic fumes produced in a 
38,000-liter chamber and those produced in the Bichel Gage and C-J Apparatus 
and relate these to explosive fumes from in-mine measurements. To carry out 
fume measurements on all types of mining explosives including blasting 
agents. 

2. Improved Instruments for Mine Gases 

Objective ; To develop personal exposure monitors such as passive, delayed 
analysis samplers for NO2 and NO^, and dosimeters for CO and NO based on elec- 
trochemical or infrared principles. To develop machine-mounted monitors for 
continuous monitoring of specific air contaminants on mobile equipment. 

3. Measurement and Control of Welding Fumes 

Objective ; To assess related industry practices pertaining to measurement and 
control of welding and cutting fumes, dust, and radiation, and adapt this 
technology to confined work areas found in the raining environment. To deter- 
mine the quantity and character of welding pollutants and personnel exposure 
levels. To propose control systems and/or isolation techniques to reduce or 
eliminate exposure to toxic substances resulting from welding and cutting. 



4. Evaluation of Industrial Hygiene Instrumentation and Equipment 

Objective ; To evaluate and verify the performance of commercially available 
or contract-developed instruments and devices for noxious and toxic gases. To 
acquire instruments and devices and evaluate their operation under varying 
conditions of temperature, humidity, and pressure. To determine the stabil- 
ity, accuracy, precision, sensitivity, and applicability to measure noxious 
and toxic gases in the mining environment. 

5. Control of Mercury Vapor Emission in Mercury Ore Processing 

Objective ; To determine the conditions under which mercury vapor is released 
during grinding and froth flotation operations, and correlate these conditions 
with measured levels of vapor emissions. To identify technology to prevent or 
control mercury vapor emissions during the milling process. 



Diesel Engines and Alternative Power Sources 

6. Control of Diesel Exhaust Contaminants 

Objective ; To supplement contract research in the control and analysis of 
diesel exhaust emissions. To measure ambient contaminants and correlate with 
emissions data. To investigate control systems for contaminants by means of 
laboratory experiments. To devise and select analytical procedures for emis- 
sion control systems and components at the tailpipe and ambient levels. 

7. Investigation of Emission Controls for Turbocharged Diesel Engines 
Operated Underground 

Objective ; To identify potential methods and hardware applicable for use as 
emission controls for turbocharged mine diesels. Work will continue to review 
the literature and monitor the current state of knowledge concerning emission 
control technology. State and international regulations pertaining to the use 
of internal combustion engines underground will be delineated. A survey of 
underground diesel population will be performed with the cooperation of MSHA. 
Applications of diesel equipment in new mining systems (e.g. , oil shale) will 
be studied. Alternative power sources that may have health and operational 
advantages over existing mine diesels will be analyzed. 

Ventilation 



Program Objectives ; To develop ventilation systems required to maintain a 
safe and healthful atmosphere conducive to efficient work output in noncoal 
mines. 

1. Development of Improved Ventilation Technology for Noncoal Mines 
and Mineral Processing Mills 

Objective ; To develop improved technologies for ventilating and cooling 
stopes and development headings in hot metal and nonmetal mines. To develop 
improved and safe methods of heating shafts in winter in order to prevent ice 



buildups and to make the transport of men comfortable. To continue to develop 
methods of ventilating dead-ended working headings in metal and nonmetal 
mines. 



SAFETY 



Fire and Explosion Prevention 



Program Objective s: To reduce the potential for fire or explosion in mineral 
extraction and processing operations; to minimize the danger to people on 
account of fires or explosions that do occur. 



Prevention Research 



1. Flammability of Coal Mine Combustibles 

Objective ; To evaluate flammability hazard of mine combustibles and develop 
improved test methods to update MSHA fire test standards. 

2. Improved Bit Materials for Continuous Coal Mining Machines 

Objective ; To reduce frictional ignitions, respirable dust, and noise, while 
also increasing productivity, by improving coal cutter bit materials. 

3. Float Dust Formation and Deposition 

Objective : To investigate rate of formation of float coal dust, size distri- 
butions of coal and rock dusts, and rate of deposition of coal and rock dusts; 
to field-test a dust deposition meter; and to conduct field investigations and 
demonstrations of engineering techniques to suppress float coal dust. 

4. Pacification of Sulfide Oxidation 

Objective ; To develop techniques and materials that will pacify the sponta- 
neous combustion of sulfide concentrates that frequently occur during mining 
and storing. 



Ignition Research 



5. Bit Impact Ignition of Methane 

Objective ; To establish operating conditions necessary to reduce the methane 
ignition probability caused by frictional impact heating during coal cutting. 

6. Thermal Ignition of Coal Dust 

Objective ; To determine mechanism of ignition, combustion, and suppression of 
coal dust flames. 



10 



7. Spontaneous Heating of Coal Mine Combustibles 

Objective ; To investigate spontaneous heating of U.S. coals and to develop 
combustion criteria for identifying incipient mine fires. 

8. Laboratory Dust Flammability Testing 

Objective ; To study the flammability of air-dispersed dust in laboratory- 
scale vessels and to correlate the data with full-scale mine studies. 



Suppression Research 



9. Prevention and Suppression of Face Ignitions and Explosions 

Objective ; To develop, test, and conduct field trials of techniques for the 
prevention and suppression of face ignitions and methane and coal dust 
explosions. 

10. Mechanisms of Flame and Explosion Suppression 

Objective ; To determine the chemical and physical processes by which gaseous 
and powdered extinguishing agents suppress flames and coal dust explosions. 

11 . Improved Mine Fire Protection 

Objective ; To improve fire safety in underground metal and nonmetal mines by 
improving early fire warning systems. 

12. Improved Fire Protection Hardware Demonstration 

Objective ; To develop improved fire protection hardware and procedures for 
mobile mining equipment. 



Propagation Research 



13. Flame Propagation Into Mine Gob Through Methane Drainage Holes 

Objective ; To determine the probability and/or conditions under which flame 
could propagate into a mine through methane-emitting boreholes. 

14. Full-Scale Mine Explosion Research 

Objective ; To increase the understanding and predictability of the initia- 
tion, propagation, and suppression of explosions of gases and dust in multien- 
try and longwall coal mines and oil shale mines, with emphasis on full-scale 
simulation in the Experimental Mine. 

15. Fire and Explosion Properties of Oil Shale 

Objective ; To continue work in the Experimental Mine, to determine the widest 
limits of explosibility of oil shale dust, as a function of kerogen content, 



11 



particle size, and with methane added to the air flow. To conduct controlled 
rubble fire tests as needed, and to coordinate cooperative projects in the 
field as opportunities arise. 

16. Physical Modeling of Mine Timber Fires 

Objective: To develop basic understanding of mine fire hazards and para- 
meters, to develop optimal means of prevention and control of mine fires, and 
to establish procedures for modeling mine fires using small-scale duct fires. 

17 . Explosion Testing of Bulkheads 

Objective: To develop specifications for strength and water tightness for 
bulkheads, seals, and retaining coal blocks. To clarify current regulations 
and to provide a basis for future regulations. 

18. Fire and Explosion Hazards of Oil Mining 

Objective: To determine the fire and explosion hazards of crude oil in the 
presence of underground mining operations. 



Extinguishment Research 



19. Sealed Coal Mine Fires 

Objective : To develop needed guidelines for safe reopening of a mine follow- 
ing the sealing of a coal mine fire. 

20. Inert Gas Generator for Extinguishment of Mine Fires 

Objective : To develop a portable inert gas generator suitable for in-mine 
extinguishment of coal mine fires. 



Detection, Instrumentation, and Alarm 



21 . Evaluate Detection Systems For Fire and Explosion Prevention 

Objective ; To develop adequate fire and explosion sensors and guidelines for 
their optimum deployment for the early warning of mine fires and explosions. 

22. Laboratory Raman Scattering Remote Methanometer 

Objective ; To determine the feasibility of remote methane detection by the 
principle of Raman scattering, to measure the Raman scattering properties of 
methane, to quantify the angular distribution of scattered light intensities 
from methane, and to determine minimum levels of methane that can be detected 
remotely. 

23. Mine (Fire) Ventilation Code, Modification and Maintenance 

Objective : To modify and verify mine (fire) ventilation simulation computer 
program to improve its applicability, usefulness, and acceptability. 



12 



24, Microscopic Structure and Composition of Combustible Dusts and Residues 

Objective : To develop pre- and post-explosion Information about the surface 
characteristics, size distribution, and compositional distribution of (1) com- 
bustible dusts and (2) mixtures of dusts and fire extlngulshants. 



Methane Control 



Program Objectives ; To develop, demonstrate, and transfer technology that will 
prevent the formation of flammable methane-air mixtures In underground mine 
workings through Improved ventilation and procedures for degaslfylng the depo- 
sit or seam In advance of and during mining. To establish correlations 
between the geology of the material to be mined and Its gas content, and to 
use these to predict methane emission hazards. 



Fundamental Factors 



1. Prediction of Coalbed Discontinuities To Increase Effectiveness of 
Drilling for Methane Drainage 

Objective : To determine fundamental factors and statistical evaluation tech- 
niques that can be used to predict coalbed discontinuities in advance of 
mining, with particular emphasis on those hazards that may adversely affect 
degasif Ication projects. 

2. Influence of Geology on Occurrence and Emission of Methane in Coal 
Measures 

Objective : To map selected coalbeds and the related geology to determine the 
gas content of coalbeds and the relationship of geology to mining and methane 
emission problems, and to assist in selecting sites for degasif ication of 
these coalbeds. 

3. Investigations of Methane in Metal and Nonmetal Mines 

Objective : To establish the origin of methane and other gases associated with 
rocks in metal and nonmetal mines and the factors influencing the migration of 
gas into those mines to provide a basis for development of control 
technologies. 

Control in Advance of Mining 

4. Use of Large-Diameter Multipurpose Borehole for Methane Control 

Objective ; To monitor to completion (upon the holes being mined through) the 
effectiveness of the multipurpose borehole for degasif ication. 



13 

5. Application of Vertical Borehole Degasif icat ion to Mine Safety 

Objective: To determine the effects of borehole spacing and methods of stimu- 
lation on reducing methane gas emissions into active mine workings by demon- 
strating the feasibility of draining gas from gassy coalbeds through vertical 
boreholes . 

6. Use of Air Shafts for Degasif iction in Advance of Mining 

Objective ; To demonstrate the utility and cost effectiveness of air shafts 
sunk in virgin coal areas, with holes drilled in the coalbeds from the bottom 
of the shafts at least 1,000 feet in depth for degasif icat ion about 5 years 
ahead of nearest mine workings. By planning future air shafts carefully, for 
more extensive degasif ication, greater productivity with increased safety can 
be achieved, and methane, a critical source of energy that has long been 
wasted from coal mines, can be conserved. 

7. Investigation of Available Equipment for Directional Drilling of Coalbeds 

Objective ; To determine the best drilling equipment presently available for 
drilling directional coalbed degasif icat ion holes in a variety of geologic 
areas. 



Control During Mining 

8. Ventilation in Control of Methane 

Objective ; This project seeks ways of improving ventilation in coal mines, 
particularly in the area of new extensible face ventilation systems. 

9. Gob Degasif ication From Underground Locations 

Objective : To drain gob gas from longwall panels by drilling in overlying 
strata. The research products will be the technical information needed by 
mine operators to implement gob degasif ication underground. Guidelines for 
all phases of this work (drilling, piping, venting, and monitoring) will be 
presented in field demonstrations and reports of investigations. 

10. Development of Control Techniques Using Horizontal Boreholes 

Objective : To demonstrate that long horizontal boreholes effectively reduce 
methane levels during mining through natural drainage. The research products 
will be field demonstrations and reports of investigations of drill equipment 
and horizontal drilling technology. 

11. Study of the Use of Water Infusion To Control Methane 

Objective : To develop improvements and new techniques for the method of water 
infusion to reduce methane levels at the working face. 



14 



12. Application of Horizontal Drilling Technology to Health and Safety 
Problems in Mines 

Objectives ; To locate and neutralize hazardous conditions such as methane 
outburst zones in coalbeds, salt mines, oil shales, abandoned mine workings, 
and methane in strata above or below in advance of mining. 



Ground Control 



Program Objectives ; To conceive, develop, demonstrate, and transfer technol- 
ogy that will prevent mine accidents attributable to falls of ground, out- 
bursts, slope failures, and collapse of waste impoundment structures. 



Premining Investigations 



1. Delineation of Abandoned Mine Workings With High-Resolution Seismic 
Techniques 

Objective ; To develop high-resolution surface seismic technology for delin- 
eating the boundaries of abandoned underground mine workings. Field tests 
will be conducted at selected mine sites, some with known abandoned workings 
and others with suspected abandoned workings, to determine the optimum seismic 
techniques for delineating the boundaries of the workings. The test results 
will be verified with the known subsurface conditions, or with drilling. 

2. Use of High-Resolution Resistivity System To Locate Abandoned Mine 
Workings 

Objective ; To establish operational techniques for a high-resolution resis- 
tivity measurement system in mining environments and' demonstrate the effec- 
tiveness of the method for hazard detection. The detection equipment fabri- 
cated under a previous contract will be tested for locating abandoned mines 
near selected active mines. 

3. Computerized Remote Sensing Techniques for Detection of Potential 
Hazards in Mine Areas 

Objective ; To develop and demonstrate rainicoraputerized methods applied to 
satellite imagery data for geologic anomaly detection in coal mines and other 
mining areas. Existing minicomputer programs will be improved and new ones 
developed to generate lineaments from Landsat Satellite imagery. Minicom- 
puter facilities will be upgraded to keep up with the state of the art 
advances. 

4. Geologic Character of Kettlebottoms and Causes of Roof Failure 

Objective ; To determine the geologic character and structure of kettle- 
bottoms, their relation to mine roof problems, and the optimum manner in which 
they can be bolted to prevent their falling from the roof. Other types of 
hazardous structures will be studied to determine their relation to roof 
failure and to develop improved roof support techniques. 



15 



5. Guidebook for Identification of Geologic Features Contributing to Roof 
Falls 

Objective ; To prepare a handbook containing sketches and photographs of geo- 
logic structures for use by geologists and nongeologists in underground geo- 
logic mapping and prediction of areas of bad roof. This handbook will be used 
to identify underground geologic features that may cause unstable roof. 

6. Prediction of Unstable Mine Roof Based on Remote- Sensing Analysis 

Objective ; To establish the relationship of linears with discontinuities in 
underground coal mines, and to verify and predict the association of photo- 
linears with unstable mine roof. Linears of selected zones will be plotted, 
and geological discontinuities that characterize the zones will be identified. 

7. Quantitative Measurement of Time Dependent Structural Behavior and 
Geophysical Properties of Coal Measure Rocks 

Objective ; To determine the time-dependent structural behavior of coal mine 
roof rocks in the laboratory for roof control planning and field implementa- 
tion. Complete the determinations of acoustic and electromagnetic properties 
of rock In two bituminous coal provinces for the Interpretation of field geo- 
physical data, including the effects of stress and moisture content. 



Selection of Mining System and Mine Opening Design 



8. Delineation of Abandoned Mine Workings With Microwave and Synthetic Pulse 
Radars 

Objective ; To finalize an operating radar-sounding system complete with mea- 
surement equipment, data enhancement processing, displays, interpretive analy- 
sis, and three-dimensional drilling instructions. This system will detect and 
characterize unknown abandoned air- and water-filled mines and geological 
structures, such as faults controlling flooding and weak rock zones. Because 
of the success to date with the radar-sounding technique in locating tunnels, 
voids, and faults to 100-foot depths, emphasis will be on the development of a 
practical system for mine personnel use. 

9. Mechanical Properties Handbook and Data Base 

Objective ; To prepare a handbook on test procedures and mechanical property 
data base for numerous types of rock encountered in metal and nonmetal mines. 
Data sets useful to mine design and ground control will be compiled from 
available files. This mechanical property information will be organized into 
a computerized numerical data base for search, retrieval, and statistical 
analysis. 

10. Ground Control Exploration and Its Application to the Design of 
Underground Coal Mines 

Objective ; To test, evaluate, and demonstrate the Bureau's technology in mine 
design and site investigation in the development of new underground coal 



16 

mines; and to develop ultrasonic instrumentation capable of measuring stress 
changes in a mine structure and premining in situ stresses in coal mines. 
Assistance will be given to the coal industry in the analysis of ground con- 
trol problems in new and existing coal mines. An ultrasonic rock stress mea- 
surement instrumentation based on NASA's pulse phase locked loop measurement 
technique will be developed. 

11. Determine Validity of Existing Blasting Proximity Criteria and Vibration 
Scaling Law 

Objective : To determine the validity of previously established damage cri- 
teria and vibration levels relative to the proximity of surface blasting oper- 
ations and underground coal mine openings. The acquisition of pertinent blast 
vibration data from different types of mining operations from a wide range of 
geologic conditions will be continued in an effort to obtain a broad data base 
representative of the maximum variation in peak particle velocity versus 
scaled distance. 

12. Analysis of Cutter Roof in Coal Mines Using the Finite Element Method 

Objective ; To demonstrate the practical applicability of the finite element 
method to determine the cause and predict the formation of a cutter roof fail- 
ure in coal min6s. The physical cause of the cutter roof failure will be 
hypothesized, and a two-dimensional finite element model will be formulated. 
It will be demonstrated analytically that a cutter roof failure can be pre- 
dicted, and measured data from the mine will be used to substantiate the 
analytical predictions. 

13. Influence of Roof and Floor Rocks on the Strength of Coal Pillars 

Objective : To demonstrate the need for taking into account the properties of 
the roof and floor rocks when estimating pillar strength by determining the 
decrease of strength that occurs when coal is tested between platens made of 
rock, rather than of steel. This impacts on the application of test data to 
coal mine design, and on future testing programs that will be conducted to 
generate design data. 

14. Ground Control Design for Room-and-Pillar and Longwall Coal Mines 

Objective ; To produce coal mine design manuals describing procedures that 
mining companies can follow, step by step, in planning new coal mines to pro- 
vide safe ground control conditions. One manual will be based largely on 
practical experience, while the other will rely more heavily on theory. 
Another objective is to develop rational and practical techniques for in situ 
measurement and determination of ground control parameters including strata 
pressure, strata displacement, mining-induced load transfer, and geomechanical 
properties of rock masses. 

15. Develop and Implement Applications Engineering Strategies for Ground 
Control Research 

Objective : To collect and evaluate the products of research activities 
related to specific, real-world problems in the field of coal mine ground 



17 



control. The range of real-world problem areas where a need exists for Bureau 
assistance In engineering applications of research results will be defined, 
and the necessary strategies will be developed to insure that such assistance 
and research products are made available to the end users, including mine 
operators, equipment suppliers, MSHA, the Office of Surface Mining, and other 
private and public sectors. The problem areas to be dealt with immediately 
are longwall mining ground control related problems resulting in accidents, 
fatalities, and poor economic performance, and the use of rock mechanics 
instrumentation to aid in solving ground control problems. 

16. Anchorage of Inundation Bulkheads in Coal Mine Openings 

Objective : To investigate various methods of anchoring inundation bulkheads 
to underground coal mine openings. A review of the state of the art of inun- 
dation bulkheads and their anchorage systems will be made. A test plan will 
be developed to evaluate the most commonly used bulkhead-anchorage systems. 
The test plan will be implemented in the Bureau's Safety Research Coal Mine. 

17. Classification of Mine Roof According to Support Mechanism Efficiency 

Objective ; To develop a systematic framework for classifying mine roof based 
on observed effective control techniques. A procedure for evaluating ten- 
sioned, point-anchored resin bolts will be developed, and the availability of 
field test sites will be assessed. The roof classification will be developed 
according to the roof bolt types and the characteristics of mine roofs that 
have been controlled in varying degrees by various support techniques. 

18. Development of Guidelines for Ground Control Under Old Workings 

Objective ; To develop guidelines for designing and using safe and effective 
ground support systems when either longwall or room-and-pillar mining under 
old workings. An analysis will be conducted to determine stress distribution 
and stability characteristics of old workings, and basic rock mechanics data 
will be obtained. As a result, a design guidebook will be published that will 
list ground conditions and the safest and most effective support systems for 
the listed conditions. 

19. Develop Improved Coal Mine Design Procedures 

Objective ; To further develop the practical application of the analytical 
techniques for planning a coal mine design by using a MINSIM-type computer 
program and a confined-core pillar design method; and then demonstrate their 
use in designing safer coal mine openings, pillars, and extraction layouts. 
An appropriate version of the MINSIM computer program will be selected, modi- 
fied, and checked; and the confined-core pillar design method will be reviewed 
and incorporated into the MINSIM program. Rock physical properties will be 
collected from in situ and laboratory measurements and used as input data for 
the computer program. The analytical results will be compared with measured 
data of mine behavior. 

20. Ground Control Design for Hard Rock Mines 

Objective ; To develop analytical design procedures and criteria that will 
reduce some of the uncertainties associated with mining systems in underground 



18 



hard rock mines. The focus will be on the interacting influence of the floor, 
roof, and support structures and its impact on overall mine stability. Pri- 
mary emphasis will be on entry development and selection of mining systems in 
evaporite deposits. 

21. Pillar Destressing in Advance of Mining 

Objective ; To demonstrate how to destress rock-burst-prone stope areas in 
advance of production mining. Instrumentation installation will be completed 
in the test block on 7900 level of the Star Mine, Idaho; and technical assis- 
tance will be given to the mine to monitor and assess a full-scale application 
of the destressing technique. 

22. Inherently Safe Mining Method for Rock Burst Control 

Objective ; To provide maintenance of Bureau instruments and technical guid- 
ance to the contractor and cooperating mining company in the demonstration of 
underhand stoping methods under Contract No. H0292013. Areas adjoining the 
test stope will be instrumented to assess redistribution of stresses in other 
critical areas during mining. 



Roof Support System 



23. Inorganic Grout for Coal Mine Roofs 

Objective ; To develop practical systems for installing fully grouted coal 
mine roof bolts with fast-set inorganic cements. Material properties for the 
inorganic full-column roof bolt systems will be determined, and field tests 
will be conducted of the water microcapsule and gypsum cement cartridges in 
selected mines. 

24. Inorganic Grouts — Materials Study 

Objective ; To provide a fundamental analysis of hydrocal plaster, quantify 
chemical and mechanical properties of the hydrocal-water capsule reaction pro- 
ducts, and examine the special qualities and problems of the hydrocal-water 
capsule system for grouting roof bolts. 

25. Concrete Crib Design and Field Test 

Objective : To complete the field demonstrations and evaluation of concrete 
cribs started in FY 80 and prepare a report on the entire project. Crib load 
and deflection Instrumentation and the physical appearance of the cribs will 
be monitored and recorded as the longwall excavation proceeds past the demon- 
stration section. Load and deflection data will be compared with the results 
predicted by the computer finite-element model prepared during FY 79. The 
structural stability, performance, and economics of the concrete crib system 
will be analyzed and compared with those of the wood support system it 
replaces. 



19 



26. Comparative Laboratory Evaluation of Resin-Grouted Roof Bolt 
Elements 

Objective ; To create a complete documentation of comparative properties of 
all resin-grouted roof support systems, making available a means of qualita- 
tive selection of bolt types by mine personnel. Also, to provide a means of 
evaluating new and innovative bolt types by comparison to standard parameters 
determined for standard bolt types. 

27. Evaluate Support Wall Systems 

Objective ; To determine the stability characteristics of various pack wall 
materials and pack systems in place. Standardized tests required to establish 
materials characteristics will be determined, test program guidelines will be 
tested to determine the overall performance ranges of a pack, and procedures 
will be established by laboratory and in-mine trials to evaluate pack compe- 
tence. Packwalls will be tested at Mid-Continent Resources, Inc. 's #1 and #3 
Mines. Laboratory tests will be performed at the Bureau's Spokane Research 
Center to establish in situ testing capabilities. Both laboratory and field 
tests of fill-in wood cribs will be conducted. 

28. In-Mine Assessment of Longwall Entry Roof Support Load Characteristics 

Objective ; To systematically gather information on the support loadings and 
strata activities that take place during any of the major loading situations, 
and to quantify and analyze this gathered data to establish rational design 
criteria and support system techniques for gateroad entries. Instrumentation 
will be installed in the gate entries and recovery rooms of two retreating 
longwall mining panels. The instrumentation will be monitored starting imme- 
diately after installation and will continue until the data are unable to be 
collected or are considered to be no longer valuable. 

29. Polymeric Sealants To Stop Shale Degradation 

Objective ; To conduct field evaluations and surveys using polymeric 
sealants to prevent shale degradation. A water-based polymeric sealant 
will be sprayed in two coal mines with follow-up patching and inspections. 
Polymeric sealants have been sprayed in two active mines in association 
with Contract H0272008, "Weathering Protection at the Face." These four 
mines will be inspected to evaluate effectiveness of the material used. 

30. Modeling Roof Bolt Systems 

Objective ; To develop guidelines for roof reinforcement using mechan- 
ically anchored bolts, full-grouted bolts, friction stabilizers, inorganic- 
grouted bolts, inclined bolts, and truss systems. The field conditions 
best suited for each bolting system will be defined. The first series 
of full-scale model tests will conducted with the roof bolt test facility 
recently completed at the Spokane Research Center. 

31. Operation and Maintenance of the Model Roof Bolt Test System 

Objective ; To operate and maintain the full-scale model roof bolt test system 
for in-house studies of roof bolting systems. The first series of full-scale 
tests of roof bolt systems will begin early in FY 81. In addition, some 



20 

concrete samples will be tested to determine the properties of the concrete 
slabs that constitute the simulated mine opening of the test facility, 

32 . Packwall Evaluation 

Objective : To develop and characterize optimum mixture designs for support 
wall materials using coal and coal waste for aggregate. 

33 . Ground Support Systems for Block Cave Mining 

Objective: To design, test, and implement better methods of support for griz- 
zly drifts and haulage crosscuts in block cave mining, and to install, line, 
and backpack a haulage crosscut at the Sacaton unit of ASARCO, Inc. 

34. Longhole Bolting Technique Development 

Objective: To develop a new expansion shell for longhole rock bolting so as 
to increase anchorage capacity in stratified and massive rocks. Preliminary 
analyses of rock bolt parameters are in progress. Fabrication and testing of 
prototypes will follow to evaluate anchorage capacity and to establish bolt 
installation standards for rock bolting in metal and nonmetal mines. 

35 . Inorganic-Grouted Bolts 

Objective : To develop an inorganic grout system suitable for the large bolt 
holes commonly drilled in metal and nonmetal mines. The initial task will be 
to identify reasons for poor anchorage of small-diameter bolts grouted in 
large-diameter holes. Pull tests will be made with different size rebar 
grouted in holes drilled in concrete blocks with a 1-3/8-inch drill (commonly 
used in metal and nonmetal mines). 

36. Corrosion of Metallic Roof Support Elements 

Objective To develop guidelines for MSHA to use in" evaluating the effective 
life of an intrinsic support system, and for industry to use to improve life 
potential of support by utilizing corrosion prevention or control measures. 



Safe Support Installation and Protection at the Face 

37 . Effects of Roof Bolt Installation Procedures on Mine Roof Stability 

Objective : To determine the effects of initial thrust on ultimate roof sta- 
bility and on the roof support system; to determine the optimum thrusts for 
installation of grouted bolts; and to develop reliable procedures for instal- 
lation of grouted bolts to obtain maximum roof stability. A full-scale test 
site will be selected and instrumented. Data will be collected, reduced, 
analyzed, and correlated to existing information. 

38 . Feasibility of Aluminum Alloy Sparking Control and Prevention Measures 

Object ive : To quantify potential problems with using aluminum temporary roof 
supports, and to investigate alloy modifications or protective coatings to 
prevent or retard spark potential. 



21 



39. Steel Support Study 

Objective ; To identify the various applications and evaluate the uses of 
steel supports in U.S. coal mines. Data for evaluation will be compiled in- 
cluding identifying uses, design criteria, installation procedures, recovery 
techniques, accident statistics related to handling and support failure, con- 
figurations available, and cost. Guidelines will be developed for use when 
designing steel support systems, taking into account European experience. 

40. Demonstration of a Concrete-Crib System in an Advancing Longwall 

Objective ; To design and demonstrate a concrete-crib support system in an 
advancing longwall operation. The field demonstration and evaluation of the 
support system will be completed, and a report will be prepared on the 
project, 

41. Angle Bolt for Cutter Type Roof 

Objective ; To field-test angle bolting to determine whether it can be used to 
control cutter-type (shear or snap top) roof, which generally cannot be con- 
trolled by conventional bolting. 

42. Automated Temporary Roof Support for Single, Fixed-Head Roof Bolting 
Machines 

Objective ; To design, fabricate, and field-test an automated temporary roof 
support (ATRS) that can be used with cab and/or canopy on single, fixed-head 
roof bolting machines. This ATRS must be set by the roof drill operator while 
in the operator's compartment under permanently supported roof. 

43. Automated Temporary Roof Support for Continuous Mining Machines 

Objective ; To design, fabricate, and field-test a self-advancing automated 
temporary roof support (ATRS) that can be used on continuous mining machines 
not equipped with integral roof drills. This ATRS must turn 60° and 90° 
crosscuts, maintain ventilation curtain within 10 feet of the face, and be run 
by the continuous miner operator while in the operator's compartment. 



Hazard Detection and Monitoring Systems 

44, Automatic Roof Fall Warning System 

Objective : To test the commercial prototype microseismic roof fall warning 
system in conjunction with a companion contract, modify the prototype system 
as necessary, and transfer the technology to the industry. The commercial 
prototype will be tested at several field sites. Both research-oriented and 
empirical experiments will be peformed in an attempt to maximize the accuracy, 
reliability, and usefulness of the systems. 



22 

45 . Laboratory and Field Study of Roof Failure Prediction in Mines 

Object ive : To determine in the laboratory the causes of the time variation of 
phenomena precursory to fracture, e.g., microseismic noise and tilt anoma- 
lies, to enable reliable prediction of imminent roof failure in coal mines. A 
digital microseismic monitoring and recording system will be installed at the 
Galena Mine, Idaho, to develop real-time analysis capabilities. Studies of 
microseismic activity and elecromagnetic radiation prior to and during rock 
failure will continue. 

46. Coal Mine Bounce and Outburst Studies 

Objective: To determine if microseismic techniques can be used to delineate 
where and when coal mine bounces and coal and gas outbursts are going to 
occur, and to establish the equipment and technology required for commercial 
application of these techniques. In addition, failure control techniques will 
be tested and assessed in terms of their effectiveness. Also, to conclude and 
evaluate the research effort in studying the effectiveness of using thermal 
anomalies prior to failure as a predictive tool for coal mine bounce. 

47. Develop Closure Rate Device for Roof Fall Prediction During Retreat 
Mining 

Objective : To design and develop an intrinsically safe closure rate instru- 
ment that will provide a means of determining closure rate at any given time 
to alert the operator to an imminent roof fall. The instrument system will 
consist of rugged retrievable extensometers to be retrieved by rope or chain 
prior to the fall and a digital readout of the measured closure with respect 
to time. The system will be designed for use in retreat mining or other areas 
too dangerous to enter once the instrument is installed and the mining cycle 
has begun. 

48. Detection of Coal Mine Roof Fall Hazards Utilizing Electromagnetic 
Sensors 

Objective : To evaluate low-frequency electromagnetics and ground penetrating 
radar systems and modify the state of the art to develop techniques to detect 
potential roof falls and other hazardous conditions in underground coal mines. 
Existing hardware will be evaluated to determine which systems could be modi- 
fied for underground use to locate and define fractures, weak strata, and 
anomalistic conditions that contibute to roof falls. 

49. Monitoring of Under Gob and Old Working 

Objective : To provide rock mechanics and mine design information, to provide 
monitoring for hazard detection when necessary, and to assemble and make 
available to industry the knowledge and techniques established through this 
effort. Work during this period will consist primarily of measuring ground 
stress physical properties and overall stability of the lower seam mining as 
mining progresses, and measuring reactions of the support systems to these 
loads and structural reactions and movements. Problem areas will be monitored 
for hazardous conditions using microseismic and other techniques. 



23 



50. In-Seam Seismeic Techniques for Hazard Detection From the Working Face 

Objective: To establish the criteria for application of guided wave propaga- 
tion for detecting hazards ahead of mining in U.S. coal seams. The effort 
will emphasize field verification of the theoretical basis for guided wave 
propagation in U.S. coal seams by conducting experiments at selected sites 
with known geologic conditions and representative targets of interest. Recom- 
mendations will be made for data processing, interpretation, and implementa- 
tion of technology. 

51. Application of Rock Burst Technology and Failure Control Methods 

Objective : To assess the positive as well as negative effects of the destress- 
ing methods presently used in the Coeur d'Alene mining district, Idaho, on 
rock burst control in the destressed stope, and incidental structural stabil- 
ity problems in the adjacent stopes. The seriousness of the resulting problems 
will be identified, and it will be determined how a minewide microseismic moni- 
toring system can best be used to allow mine personnel to assess their des- 
tressing program techniques on a continuing basis. Field tests will continue 
in the Galena Mine, and the test data will be analyzed to establish more con- 
clusive evidence of the potential of microseismic prediction of rock 
bursts. 

52. Prediction and Control of Rock Bursts and Failures in Mines 

Objective : To develop effective and reliable methods of predicting rock 
bursts and controlling burst-prone stopes; to apply these methods to a mine 
with burst-prone stopes; and to determine criteria and procedures basic to the 
problem of establishing mine structure stability and how structural instabil- 
ities contribute to mine failures. Data obtained from the digital micro- 
seismic system at the Galena Mine, Idaho, will be compared with the analog 
system currently employed at the mine, and an effort will be made to idenify 
anomalous zones prior to bursts and to characterize microseismic activity from 
stressed and destressed material. Laboratory studies to test the inclusion 
theory of rock failure and further examination and documentation of electro- 
magnetically induced discharges caused by failure of rock materials exhibiting 
piezoelectric effects will continue. 

53. Slope Failure Detector 

Objective ; To field-test and improve a microseismic slope failure detection 
system that can be used in an open pit mine to forewarn mine management of 
Impending slope failure so that proper safety precautions can be taken. Field 
monitoring will be completed at the Morenci Mine of Phelps Dodge Corp., 
Arizona, using the monitoring system developed by the Bureau. 

54. Improved Roof-Sounding Techniques and Equipment 

Objective ; To establish the technology and equipment to insure improved abil- 
ity to determine the condition of roof areas in freshly mined openings. To 
reexamine past work aimed at using dynamic techniques for measuring the sound- 
ness of roof rock in freshly mined openings. To execute new studies, using 
In-house equipment to determine the most promising avenues and methods to 
pursue. To begin execution of field studies to establish feasibility, 



24 



practicality, and reliability of measuring the dynamic response of roof rock. 
To establish initial data analysis procedures. 

55. Guidelines for Comprehensive Rock Burst Detection Plans 

Objective ; To document instrumentation data from previous and ongoing rock 
burst studies to assist mine operators in designing comprehensive rock burst 
detection plans for their mines. 



Mining and Minerals Processing Waste Stability 

56. Evaluation of Filter Cloth for Stabilization of Coal Mine Wastes 

Objective ; To evaluate the criteria for selection of filter cloth to control 
seepage in coal mine waste dams. Laboratory tests of various filter cloths 
will be conducted under simulated mine waste dam environments, and preliminary 
guidelines for use of filter cloths in coal mine waste dams will be developed. 

57. Consolidation of Coal-Clay Wastes by an Improved Flocculation Technique 

Objective ; To demonstrate the technical feasibility of using an improved 
flocculation technique to dewater waste coal sludge generated in coal prepara- 
tion plants to produce a consolidated stable waste material containing 50 or 
more weight-percent solids that can be safely stored. Laboratory investiga- 
tions will optimize flocculation and consolidation parameters and establish 
mass flow rates. Based on laboratory investigations, a larger scale field 
test unit will be designed and assembled. The feasibility of mixing dewatered 
coal sludge with coarse coal refuse material for long-term stabilization of 
both waste products also will be demonstrated. 

58. Mixing Coarse and Fine Coal Wastes 

Objective ; To determine optimum mixing ratios of coarse and fine coal wastes 
to achieve maximum fill strengths for surface disposal, and to develop a 
method to mix and transport the mixtures while minimizing segregation. 
Samples of coal wastes will be obtained from preparation plants that mix fine 
and coarse coal wastes and that impound fine coal wastes behind an embankment 
of coarse wastes. Fill strengths of coarse and fine wastes will be determined 
by laboratory tests. A report on the waste disposal practices at the coal 
preparation plants visited will be prepared. 

59. Alternative Coal Waste Disposal Methods 

Objective ; To complete physical property tests of coarse anthracite coal 
waste, to collect Shelby tube samples of anthracite fine waste and determine 
their physical properties, and to conduct laboratory model tests simulating 
injection of fine waste particles into voids created by coarse waste. Injec- 
tion of fine waste particles into voids is aimed at increasing the support 
capability of backfilling and other waste disposal methods. 



25 

60. Factor of Safety-Risk Analysis In Tailings Embankments Design 

Objective : To apply techniques of operations research and statistics to the 
design of tailing dams, establish a confidence Interval or level of uncer- 
tainty about the factor of safety, Investigate state of the art sampling pro- 
cedures for tailings embankments, and construct simplified factor-of-safety 
charts for field applications and for Industry's use. Sampling procedures now 
used to ascertain the safety of existing tailings embankments will be Investi- 
gated, and a statistical procedure to be applied to on-site embankment main- 
tenance and control will be developed. 



Industrial-Type Hazards 



Program Objectives ; To (1) limit the possibility of human error through 
training and worker-machine interfacing, (2) Improve equipment design and con- 
trols, (3) detect and prevent failures of electric circuitry and hardware, (4) 
provide adequate lighting in working areas, (5) insure continuous and reliable 
communication between all underground and surface mine personnel, while pro- 
viding continuous surveillance of the mine environment, and (6) Improve safety 
in haulage and materials-handling operations. 



Human Factors 



1. Surface Mining Training 

Objective : To develop information and strategies to aid mining companies and 
MSHA in implementing and monitoring effective training programs. A report 
entitled "Training Evaluation for the Minerals Industry: A Literature Survey" 
will be completed. 

2. Human Factors and Industrial Safety 

Objective ; To investigate and develop new human-factors-related programs and 
to support ongoing contract efforts in this area. The shuttle car and con- 
tinuous miner training system will be evaluated with respect to future work 
station and control-display design research. 



Electrical 



3, Electrical Ignition Hazards 

Objective ; To Investigate research problems related to intrinsic safety and 
explosion-proof enclosures. Technical support to Bureau programs and MSHA, 
and cooperation with national and international committees engaged in devel- 
oping standards for the use of electrical equipment in potentially explosive 
atmospheres will be provided. 



26 



4. Electrical Equipment, Devices, and Systems 

Objective ; To conduct preliminary Investigations and final evaluations rela- 
ting to contracted research and design tasks In the field of mine electrical 
systems and devices. Technical assistance will be provided to MSHA and the 
mining industry. 

5. Handbook for Electrical Grounding Safety for Small Pits and Quarries 

Objective ; To develop a comprehensive handbook for field use concerning 
grounding practices for the small surface operator. Proper grounding proce- 
dures will be identified and presented in an easy-to-understand, "how to" for- 
mat for use by operators of small pits and quarries. 



Equipment 



6. Participation on Society of Automotive Engineers (SAE) Technical 
Committee on Mining Equipment 

Objective ; To allow Bureau personnel to actively participate on the SAE Tech- 
nical Committee" on Mining Equipment. The committee develops standards that 
cover requirements for safeguarding life and property on underground and sur- 
face mining equipment. 

7. Equipment Development 

Objective ; To continue evaluation of brakes and development of safe re- 
railing techniques. Investigation of antlreverse motor locks and evaluation 
and development of low-speed measurement technology will also be undertaken. 

8. Machinery-Maintenance-Related Accidents — Evaluation of Existing Data 

Objective ; To determine and quantify the specific hazards and reasons for 
maintenance and repair-related accidents in the coal mining industry. In 
close cooperation with MSHA, Industry, and MSHA's Health and Safety Analysis 
Center, accident data will be collected and analyzed. Identified mitigatible 
health and safety problems will be categorized and ranked on a research prior- 
ity basis. 

9. Field Testing and Evaluating a New Improved Seat and Seat Belt System for 
Surface Mining Equipment 

Objective : To evaluate operator acceptance of improved seat belt systems 
developed under contract by the Bureau. The new systems will be Installed and 
tested in-mine with operator acceptance being monitored by observations and 
interviews. 

10. Evaluation of Cracklike Discontinuities of Rollover Protective Structures 

Objective : To define and characterize the service life of ROPS on surface 
mining equipment. Cracks in the welds and materials used in ROPS will be 
analyzed to determine the cause of these types of failures. 



27 

11 . Collision Protection Systems for Large Mobile Mining Equipment 

Objective : To develop and in-mine test prototype systems to reduce the vehi- 
cle collision hazard in surface mines. As vehicle size increases, reduced 
driver field of vision increases the collision danger. Ruggedized, reasonably 
priced prototype hardware will be developed to reduce this hazard. 

Illumination 

12. Mine Illumination 

Objective: To investigate the illumination of surface mining equipment. Spe- 
cialized power supplies will be evaluated and a computer-based system to 
photometrically evaluate mine illumination hardware will be developed. Tech- 
nical assistance will be provided to MSHA and the mining industry. 

13. Recommendations for Minimal Luminance Requirements for Metal and Nonmetal 
Mines 

Objective : To define minimum luminance requirements for various job tasks and 
work areas in metal and nonmetal underground mines. The purpose is to provide 
overview information and supportive data for the formulation of illumination 
standards . 



Nonemergency Communications 

14. Mine Telemetry and Environmental Surveillance Systems 

Objective : To design, procure, laboratory-test, and in-raine evaluate an in- 
trinsically safe mine monitoring system. Performance levels of the total sys- 
tem will be established and analyzed. 

15. Performance Standards and Systems Approach to Mine Monitoring 

Objective : To conduct preliminary investigations and maintain a base of know- 
ledge in the areas of mine monitoring system safety, evaluation, equipment de- 
sign, and equipment performance evaluation. Work will concentrate in the 
areas of equipment reliability, data transmission security, sensor evaluation, 
and safety evaluation. 

16. Underground Communication Systems 

Objective : To develop and field-evaluate special systems and hardware for the 
purpose of improving underground communications, monitoring, and control. 
Systems based on new technologies such as fiber optics, short-range VHP, and 
microwaves will be investigated. Basic measurements on phone lines and free 
space propagation will be conducted to expand baseline data in these areas, 
and assistance will be given to the mining industry in solving any specific 
communication problems. 



28 



17. Development of Head-Worn Coal Face Communication Systems 

Objective : To develop a head-worn communications system that is integrated 
into a miner's hat. The device will address the problem of the loss of cap- 
lamp signaling ability in illuminated low-coal environments. Existing head- 
worn communication systems that were designed for other industrial applica- 
tions will be redesigned and integrated into an approved miner's hat. 

18. Communications Equipment for Sunshine Mine 

Objective ; To purchase communications equipment and associated items in sup- 
port of the ongoing demonstration of communication, telemetry, and monitoring 
systems at the Sunshine Mine. 

19. Communications Equipment for Black River Mine 

Objective ; To purchase communications and monitoring and fire detection 
equipment in support of the ongoing demonstration of communication, telemetry, 
and monitoring systems at the Black River Mine. 



Haulage and Materials Handling 



20. Laboratory Analysis of Wire Rope 

Objective ; To define characteristics of wire rope that affect rope degrada- 
tion during use in mine hoisting. Mechanisms of wire rope failure will be de- 
termined by monitoring rope through field use and by laboratory analysis of 
retired rope specimens. 

2 1 . Fatigue Testing of Wire Rope 

Objective ; To conduct fatigue tests that can be used as a basis for wire rope 
retirement criteria. Fatigue tests will be conducted on wire rope to deter- 
mine rope life at different loads and to determine when appropriate safety 
factors have been met. Recommendations on retirement criteria will be made on 
the basis of the fatigue tests. Data will be used to improve retirement cri- 
teria standards, aid users in proper rope selection, and aid MSHA safety 
regulation. 

22. Materials-Handling Equipment Development 

Objective ; Investigate methods by which various facets of materials-handling 
activities can be made less human-labor intensive. Particular areas of inter- 
est would be the transfer and handling of machine components during mainte- 
nance activities, the handling of fall debris, and research in support of con- 
tractual efforts in this area. This effort will design and construct proto- 
type devices to minimize the human handling of underground supplies. The 
devices will be evaluated in operating mines. 

23. Shaft Maintenance Guidelines 



Objective ; To identify the hazards associated with shaft and slope repair and 
maintenance. Maintenance and repair procedures will be reviewed, and guide- 
lines will be prepared that will improve safety. 



29 



24. Surface Mine Equipment Safety 

Objective: To develop and demonstrate new mobile mine vehicle safety hardware 
in the areas of vehicle towing, driver alertness, and operator ingress and eg- 
ress systems. 

25. Laboratory Analysis of Wire Rope 

Objective ; To define characteristics of wire rope and its use that affect its 
service life. New and retired rope specimens will be analyzed, and rope usage 
in the field will be monitored. Manufacturing procedures, wire rope mate- 
rials, and in-service procedures that have potential for improving the perfor- 
mance and safety of wire rope used in mining will be defined. 



Post Disaster 



Program Objectives ; To develop technology that will (1) enable survivors of a 
mine disaster to escape from the mine or to continue to survive while awaiting 
rescue by providing protection against toxic and/or oxygen-deficient atmos- 
pheres, (2) aid in the location of miners trapped underground, using seismic 
and electromagnetic means of communication, and (3) facilitate post disaster 
rescue and recovery operations through surface monitoring of conditions under- 
ground, emergency communications, and mechanized transport and life-support 
equipment for mine reentry and rescue operations. 



Survival 



1. Development of Life Support Technology 

Objective ; To investigate, evaluate, and further develop advanced life- 
support technology for use in coal mines for self-rescue and rescue team oper- 
ations. Specific products include a prototype rescue apparatus, several 
reports useful to MSHA and industry in developing escape standards, and evalu- 
ations of new oxygen self -rescuers and rescue breathing apparatus. 

2. Improved Oxygen Sources for Breathing Apparatus 

Objective ; To develop solid chemicals that provide more oxygen per unit 
weight than the potassium superoxide presently used in self-contained 
breathing apparatus. 



Communications 



3. Trapped Miner Location and Communication 

Objective ; To develop emergency detection and location systems for post dis- 
aster rescue efforts, evaluate hardware for same, and provide technical 
assistance to contractors conducting field test programs. 



30 

4. Development of Trapped Miner Location System Using Phase Difference of 
Arrival Techniques 

Objective : To determine the feasibility of using "phase difference of arrival 
concepts" (PDOAC) to develop an electronic system for locating trapped miners. 
The use of PDOAC to make a three-dimensional estimate of the location of a 
miner trapped below the earth's surface should greatly improve present tech- 
nology for such measurements. 

5. Short-Range Location 

Objective: To develop an EM transmitter device that can be incorporated into 
a miner's lamp battery and/or a passive device that can be activated remotely 
that will enable rescuers within a 20- to 30-meter radius to accurately locate 
the source of transmission. 



Explosives 



Program Objectives : To assess the problems associated with the safe and 
effective use of explosives in all types of mining activity; these include 
fixed explosives^ blasting agents, blasting devices, and blasting accessories. 
To conduct fundamental studies of explosive behavior and apply the results in 
the development of new technology. To develop new and improved test proce- 
dures as new mining methods are introduced and new types of explosives are 
formulated. 

Blasting Agents and Other Hazardous Chemicals 

1 . Permissible Exposive Evaluation and Research 

Objective : To explore and resolve problems associated with safe and effective 
use of underground coal mine explosives in gassy and dusty mines. The re- 
search program will include a study of the causes of misfires and deflagra- 
tions occasionally reported for permissible water gels. New formulations pre- 
pared by other Bureau personnel will be tested in the gallery; this supportive 
work is part of an effort to control the incendivity of water gels with chemi- 
cal additives. Work will include testing new permissibles, field samples, and 
explosives involved in mine incidents. 

2. Development of New Schedule Tests and Standards 

Objective : To develop standards for permissible explosives, explosive de- 
vices, and blasting accessories, and to develop test procedures and basic 
knowledge of explosive incendivity in support of the standards. Schedules and 
related tests will be developed for stemming devices and other explosive- 
actuated devices. The problems of desensitizat ion of water gel explosives by 
extreme temperatures and dynamic desensitizat ion leading to misfires will be 
investigated. In addition, the mechanisms of ignition of flammable atmos- 
pheres by shot firing will be investigated. 



31 

3. Hazards of Explosives and Explosive Devices 

Objective: To produce data, supply infonnation, and make recommendations re- 
lating to the sensitivity of explosives and initiating devices to impact, 
friction, thermal, and electrostatic stimuli. Optimum designs for antielec- 
trostatic devices for electric detonators will be developed. Research for an 
ultrasafe detonator will continue, applying results of ant ielectrostat ic 
studies and incendivity studies from related projects. Sensitivity tests will 
be conducted in connection with investigations of misfire accidents. 

4. Fire Hazards of Explosives and Blasting Agents 

Objective : To produce data in support of the development of standards for the 
storage and handling of explosives and blasting agents. Large-scale (field) 
burning tests of explosives and blasting agents will be conducted, based on 
information gathered from laboratory experiments. Laboratory-scale determina- 
tions of ignitibility, burning rate, sensitization at elevated temperatures, 
and tendency to detonate during combustion will be continued for these explo- 
sives. Laboratory and field test results will be correlated, in order to pro- 
vide a set of test procedures and standards for determining tendency to 
detonate. 

5. Development of New Explosive Systems 

Objective : To develop safer and more efficient explosives for the mining 
industry, evaluate basic sensitization processes in water gel explosives and 
blasting agents, and examine the effects of chemical species and degree of 
confinement on incendivity of permissible explosives. 

6. Analysis of Mine Blasting Accidents 

Objective : To analyze mine and construction blasting accidents and incidents 
to insure that the Bureau research effort is directed toward the real causes 
of blasting accidents. 

7. Prepare a Practical Blasting Handbook 

Objective : To prepare a practical blasting handbook to meet the needs of 
industry and Government agencies. 

Systems Engineering 

Program Objectives ; To develop mathematical models for evaluating the impact 
of specific technological improvements or inadequacies on the total mining and 
minerals processing operations and identifying problems whose solution would 
provide the greatest health and safety benefit. To operate and maintain 
underground research and test facilities for use in testing and demonstrating 
new procedures and equipment, before they are field-tested in commercial 
mines. To participate in contract development and in the formulation of 
mining and minerals processing health and safety standards. 



32 



Systems Analysis 



1 . Planned Application of Research Results to Mining Operations 

Objective : To examine, select, process, and package pertinent Bureau research 
results related to coal mine safety, efficiency, and conservation in order to 
effectively integrate them into the total mining system. Also, to identify 
technology gaps in research and to improve techniques of planning, designing, 
and operating underground coal mines. 

2. Establish Mine Vehicle Environmental Parameters for Component 
Specification Requirements 

Obiective: To qualify and quantify mine vehicle environmental parameters so 
that realistic design specifications for mine vehicle components can be 

developed. 

3. Statistical Accident Analysis and Literature Research 

Objective : To define patterns in mining accidents by applying appropriate 
statistical analysis techniques to Health Safety Analysis Center (MSHA) mining 
accident data. To establish ways of reviewing, organizing, and summarizing 
past research with intent to apply it to current industry problems. 

4. Economics of the Application of Improved Health and Safety Hardware 

Objective : To determine the cost effectiveness of specific Bureau-developed 
safety devices. 



Test Facilities 



5 . Operation of the Experimental Mine and Safety Research Coal Mine 

Objective : To maintain and operate the two mine facilities at Bruceton, Pa., 
that are used for coal mine health and safety research problems. The under- 
ground mines must be maintained in safe and proper operating condition in 
order to conduct full-scale experiments on explosives, dust suppression, roof 
control, ventilation, fire and explosion prevention and suppression, haulage 
safety, communications, mines surveillance, and related facets of coal mine 
health and safety research. 

6. Operation of the Lake Lynn Experimental Test Facility 

Objective : To maintain and operate the Bureau's new full-scale underground 
multiple-entry facility and evaluate the effectiveness of various techniques 
developed for extinguishing coal dust explosions. Included in the testing are 
extinguishment hardware, ignition quenching devices, and passive and triggered 
barriers. These studies provide information on the velocity and length of 
flames, the velocity and pressure waves in advance of flame front, composition 
of gases at various stages of explosions, and other physical and chemical 
phenomena associated with gas and coal dust explosions. 



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